Strap-type vehicle-to-crossbar coupler assembly

ABSTRACT

A rack for carrying cargo on top of a vehicle that may include a crossbar and a pair of coupler assemblies for connecting opposing ends of the crossbar to raised rails on top of the vehicle. Each coupler assembly may include a body, a securing assembly to secure the body to the raised roof rail, and a crossbar clamp, where the securing assembly and the crossbar clamp are independently adjustable.

CROSS-REFERENCES

This application is based upon and claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 62/173,333, filed on Jun. 9, 2015, and U.S. Provisional Patent Application Ser. No. 62/175,192, filed on Jun. 12, 2015, which are incorporated herein, in their entireties, for all purposes.

The following related applications and materials are incorporated by reference, in their entireties, for all purposes: U.S. Pat. No. 6,905,053; U.S. Pat. No. 8,333,311; U.S. Pat. No. 8,393,508; U.S. Pat. No. 8,544,707; U.S. Pat. No. 9,132,782; U.S. Pat. No. 9,283,884; U.S. patent application Ser. No. 15/167,774; and U.S. patent application Ser. No. 15/172,043.

FIELD

This disclosure relates to systems and methods for attaching cargo racks to vehicles. More specifically, the disclosed embodiments relate to couplers for attaching a crossbar of a cargo rack to a vehicle equipped with raised roof rails.

INTRODUCTION

Popularity of recreational activities continues to grow, with a corresponding growth in the need for carrying recreational equipment and cargo on vehicles. Accordingly, various equipment carriers and accessories have been developed over the years, for recreational items such as bicycles, skis, surf boards, standup paddle boards, kayaks, and the like. Many such carriers and accessories are supported on rooftop racks.

Rooftop racks typically include crossbars mounted to the vehicle roof, and the crossbars themselves may be of various shapes and sizes, from square to round to aerodynamic. Meanwhile, the number of different vehicle rooftop configurations has grown as well, with various shapes, sizes, and features depending on the make and model of the vehicle.

A need exists for a coupler capable of easily and securely attaching a crossbar of a cargo rack to a roof-mounted raised rail of a vehicle, and in particular where the coupler may additionally be compatible with a variety of crossbar types and configurations.

SUMMARY

The strap-type vehicle-to-crossbar coupler, as well as related systems and methods according to the present teachings, allow attachment and actuation of various crossbars and crossbar clamps to a vehicle having raised roof rails.

In some embodiments, a rack for carrying cargo on top of a vehicle may include a crossbar for carrying cargo on top of a vehicle and a pair of coupler assemblies configured for connecting opposing end portions of the crossbar to raised rails on top of the vehicle. Each coupler assembly may include a body configured to rest upon an upper surface of the raised rail, and a securing assembly configured to secure the body to the raised roof rail, where the securing assembly may include a resilient strap having a first end and a second end, the first end being attached to the body and the second end being selectively attachable to the body, so that the intervening portion of the resilient strap passes beneath the raised roof rail. The coupler assembly may also include a strap tightening mechanism configured to reversibly shorten the effective length of the retention strap to secure the body to the raised roof rail. The coupler assembly may further include a crossbar clamp having a crossbar seat disposed on an upper surface of the body, a crossbar connector that is complementary to the crossbar and movable relative to the crossbar seat, and a crossbar clamp mechanism configured to urge the crossbar, via the crossbar connector, against the crossbar seat. The securing assembly and the crossbar clamp may be independently adjustable.

In some embodiments, a coupler assembly may include a body configured to rest upon an upper surface of the raised rail, and a securing assembly configured to secure the housing to the raised roof rail, where the securing assembly may include a resilient strap having a first end and a second end, the first end being attached to the body and the second end being selectively attachable to the body, such than an intervening portion of the resilient strap passes beneath the raised roof rail, and a strap tightening mechanism configured to reversibly shorten the effective length of the retention strap when a first actuator is rotated and thereby secure the body to the raised roof rail. The coupler assembly may include a crossbar clamp having a crossbar seat disposed on an upper surface of the housing, a crossbar connector that is complementary to the crossbar and movable relative to the crossbar seat, and a crossbar clamp mechanism configured to urge the crossbar, via the crossbar connector, against the crossbar seat when a second actuator is rotated. The first actuator and the second actuator may be independently adjustable.

In some embodiments, a rack for carrying cargo on top of a vehicle may include a crossbar for carrying cargo on top of a vehicle and a pair of coupler assemblies configured for connecting opposing end portions of the crossbar to raised rails on top of the vehicle. Each coupler assembly may include a body configured to rest upon an upper surface of the raised rail, and a securing assembly configured to secure the body to the raised roof rail. The securing assembly may; include a resilient strap having a first end and a second end, the first end being attached to the body and the second end being selectively attachable to the body, such than an intervening portion of the resilient strap passes beneath the raised roof rail, and a strap tightening mechanism configured to reversibly shorten the effective length of the retention strap when a first actuator is rotated and thereby secure the body to the raised roof rail. Each coupler assembly may; further include a crossbar clamp having a crossbar seat disposed on an upper surface of the housing, a crossbar connector that is complementary to the crossbar and movable relative to the crossbar seat, and a crossbar clamp mechanism configured to urge the crossbar, via the crossbar connector, against the crossbar seat when a second actuator is rotated. The first actuator and the second actuator may be independently adjustable, have substantially parallel axes of rotation, be disposed on an outboard side of the housing, and be configured to be adjusted using a single tool.

Features, functions, and advantages may be achieved independently in various embodiments of the present disclosure, or may be combined in yet other embodiments, further details of which can be seen with reference to the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic block diagram of a rooftop cargo rack system.

FIG. 2 is an oblique isometric view of a portion of an illustrative vehicle showing an illustrative rooftop rack mounted to the raised rails thereon.

FIG. 3 is a partially schematic diagram of an illustrative strap-type crossbar-to-vehicle coupler in accordance with aspects of the present disclosure.

FIG. 4 is a perspective view of an illustrative strap-type crossbar-to-vehicle coupler having an outboard portion of the coupler case removed.

FIG. 5 is an elevation view of the coupler of FIG. 4 from the outboard side, with the locking feature removed.

FIG. 6 is a cross-sectional perspective view of the coupler of FIG. 4.

FIG. 7 is a cross-sectional side elevation view of the coupler of FIG. 4.

FIG. 8 is a cutaway perspective view of the clamp actuator and securing assembly of the coupler of FIG. 4.

FIG. 9 is a schematic view showing various possible combinations of illustrative crossbars and clamps with a strap-type crossbar-to-vehicle coupler via an actuator, in accordance with aspects of the present disclosure.

FIG. 10 is an isometric view of an illustrative crossbar clamp suitable for round crossbars.

FIG. 11 is an isometric exploded view of another illustrative crossbar clamp suitable for slotted crossbars.

FIG. 12 is an end elevation view of the crossbar clamp of FIG. 11 assembled and installed in an illustrative slotted crossbar.

FIG. 13 is an isometric view of another illustrative crossbar clamp suitable for aerodynamically shaped crossbars.

FIG. 14 is an isometric exploded view of an illustrative crossbar clamp and crossbar clamp actuator assembly in accordance with aspects of the present disclosure.

FIG. 15 is a bottom plan view of a traveling wedge block of the actuator assembly depicted in FIG. 14.

FIG. 16 is a side elevation view of a wedge follower of the actuator assembly depicted in FIG. 14.

FIG. 17 is a top plan view of the wedge follower of FIG. 16.

FIG. 18 is an end elevation view of the wedge follower of FIG. 16.

FIG. 19 is a partial, sectional, elevation view of an illustrative coupler and crossbar, showing an actuator and crossbar clamp in a first, unclamped configuration.

FIG. 20 is a partial, sectional, elevation view of the coupler and crossbar of FIG. 19, showing the actuator and crossbar clamp in a second, clamped configuration.

DESCRIPTION

Various aspects and examples of strap-type crossbar-to-vehicle couplers suitable for use with a variety of crossbar clamp actuators and crossbar clamps, as well as related systems and methods, are described below and illustrated in the associated drawings. Unless otherwise specified, a strap-type coupler according to the present teachings and/or its various components may, but are not required to, contain at least one of the structure, components, functionality, and/or variations described, illustrated, and/or incorporated herein. Furthermore, unless specifically excluded, the process steps, structures, components, functionalities, and/or variations described, illustrated, and/or incorporated herein in connection with the present teachings may be included in other similar devices and methods, including being interchangeable between disclosed embodiments. The following description of various examples is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. Additionally, the advantages provided by the examples and embodiments described below are illustrative in nature and not all examples and embodiments provide the same advantages or the same degree of advantages.

DEFINITIONS

The following definitions apply herein, unless otherwise indicated.

“Comprising,” “including,” and “having” (and conjugations thereof) are used interchangeably to mean including but not necessarily limited to, and are open-ended terms not intended to exclude additional, unrecited elements or method steps.

Terms such as “first”, “second”, and “third” are used to distinguish or identify various members of a group, or the like, and are not intended to show serial or numerical limitation.

The terms “inboard,” “outboard,” “forward,” “aft,” and the like are intended to be understood in the context of a host vehicle on which systems described herein may be mounted or otherwise attached. Terms regarding lateral orientation or positioning may be considered relative to an imaginary central vertical plane dividing the vehicle into left and right sides. For example, “outboard” may indicate a relative position that is laterally farther from the central vertical plane, or a direction that is away from the central vertical plane. Conversely, “inboard” may indicate a direction toward the central vertical plane, or a relative position that is closer to the central vertical plane. Similarly, “forward” means toward the front of the vehicle, and “aft” means toward the rear of the vehicle. In the absence of a host vehicle, the same directional terms may be used as if the vehicle were present. For example, even when viewed in isolation, a crossbar may have a “forward” edge, based on the fact that the edge in question would be installed facing the front portion of a host vehicle.

Overview of a Roof Rack System

In general, and with reference to FIG. 1, a vehicle roof rack system 10 may include any suitable combination of components configured to removably and securely affix a selected crossbar to a vehicle rooftop. The crossbar is supported at either end by a pair of supports having features that facilitate attachment to corresponding feature(s) on the specific host vehicle. The crossbar supports may also be referred to as towers, feet, or mounts, and are referred to herein as couplers. A versatile and efficient system may be provided to fit a selected crossbar to the wide range of vehicle rooftops present in the marketplace.

Accordingly, roof rack system 10 may include one or more types of crossbars 12 suitable for use on a range of vehicles. Each type of crossbar 12 may include any suitable crossbar configured to be mounted transverse to the longitudinal axis of a vehicle, across a rooftop, and to support loads placed thereon. For example, a crossbar 12 may support a bicycle carrier, ski carrier, kayak carrier, and/or the like. Crossbars are typically mounted on a vehicle in pairs, such that a forward and an aft crossbar are present on the host vehicle for proper load carrying. Crossbars 12 may have any suitable cross section, such as round, square, teardrop, aerodynamic, and/or any other suitable shape or combination of shapes. Specific embodiments of crossbars 12 are described in further detail below.

Crossbars 12 are supported by attaching or fastening each of the crossbars to one or more specific vehicle features 14. Vehicles come in many shapes and sizes, with a corresponding array of roof topologies. Vehicle features 14, to which the crossbars may be attached, can include raised rails running along lateral sides of a rooftop, flush rails with no space between the rails and the roof, channels or hard points on the roof, side edges or gutters of a naked roof, and/or the like.

To fasten the outboard ends of the crossbars to features 14, system 10 may include one or more couplers 16, also referred to as supports, towers, feet, or mounts, as mentioned above. Each coupler 16 may include any suitable vehicle interface 18 configured to attach, clamp, and/or removably connect to one or more vehicle features 14. Each coupler 16 may also include any suitable crossbar interface 20 configured to provide an attachment point or mount for a crossbar 12.

In some examples, crossbar interface 20 may include a universal interface for connecting a variety of crossbars. Each specific crossbar 12 may include or be associated with a crossbar connector 22 (also referred to as an adapter) configured to comprise a crossbar-specific bar clamp 24 when combined with a crossbar seat 26. Crossbar interface 20 may include a threaded bolt protruding upward from support 16. In this example, crossbar connector 22 may include a threaded portion for receiving the threaded bolt, as well as a holder portion for gripping, grasping, or grabbing onto the specific crossbar. Various crossbar connectors may each be attachable, interchangeably, to the same threaded bolt of the interface.

Bar clamp 24 may be used to removably and securely attach crossbar 12 to coupler 16. Accordingly, crossbar interface 20 of coupler 16 includes a crossbar (or bar) clamp actuator 28 configured to tighten, draw together, or otherwise cause clamp 24 to securingly engage the crossbar. Bar clamp actuator 28 may include a manual actuator or manual actuating mechanism. Illustrative examples of bar clamp actuators 28 are described in detail below.

Crossbar connector 22 and/or crossbar seat 26 may be grouped or provided with crossbar 12 to form a kit suitable for connecting to remaining elements of crossbar interface 20 of one or more different couplers 16. In other examples, crossbar connector 22 and/or crossbar seat 26 may be grouped or provided with coupler 16, to form a customized coupler suitable for connecting to a specific crossbar 12. From these examples, it should be clear that selected combinations of subcomponents of system 10 may be provided independently or separately, and combined or assembled as appropriate (e.g., for a specific vehicle).

In some examples, coupler 16 may include a body or body portion 30 providing structural and/or other functional aspects of the coupler, e.g., locking devices, environmental, aesthetic, and/or aerodynamic outer housing features, internal support structure, etc. Vehicle interface 18 and/or crossbar interface 20 may be attached, unitary with, and/or coupled to coupler body portion 30. Alternatively or additionally, crossbar interface 20 and vehicle interface 18 may be coupled to each other.

Vehicle interface 18 may include any suitable structure and/or device configured to removably attach to a given vehicle feature (or features) 14. For example, vehicle interface 18 may include a clamp, hook, bolt, clip, strap, and/or the like, and/or any combination of these. To provide an efficient and versatile system, a selected number of vehicle interface types may be provided, some having modifiable or selectable components for further customization. Specific examples of vehicle interfaces 18 are mentioned in the examples below.

Accordingly, system 10 may allow a user to choose a crossbar 12, select a coupler 16 having a vehicle interface 18 appropriate for attachment to vehicle feature 14 of the user's vehicle, and clamp the crossbar to the support using a corresponding clamp comprising crossbar connector 22 and crossbar seat 26.

Turning to FIG. 2, a specific example of a roof rack 40 is depicted, attached to an illustrative roof 42 of a vehicle 44. Roof rack 40 is a selected example of roof rack 10, described above. Accordingly, similar components may be labeled with similar reference numbers. Rack 40 may be used for carrying cargo and/or cargo-specific accessories on top of vehicle 44. Vehicle 44 has a longitudinal axis 46 generally coinciding with (e.g., running parallel to) a direction of vehicular travel 48.

Rack 40 includes a pair of crossbars 50 and 52 having aerodynamic shapes and attached to raised rail features 54 and 56 of vehicle roof 42. Each crossbar is supported and mounted on vehicle 44 by a respective pair of couplers configured to mount the crossbar on top of the vehicle with the crossbar substantially perpendicular to longitudinal axis 46. Accordingly, crossbars 50 and 52 are substantially parallel to each other and oriented across a width of the vehicle roof, as generally indicated by a lateral axis 58 in FIG. 2. Crossbar 50 is mounted on top of the vehicle by couplers 60 and 62, and crossbar 52 is mounted on top of the vehicle using couplers 64 and 66. Couplers 60, 62, 64, and 66 each include a crossbar interface 20 comprising a selected crossbar clamp and actuator, as well as a vehicle interface 18 for clamping or otherwise connecting the coupler to a vehicle feature.

In the example depicted in FIG. 2, couplers 60, 62, 64, 66 are strap-type couplers suitable for connecting the coupler to the raised rail features 54 and 56 of vehicle 44. Strap-type couplers may include strap that extends from a body of the coupler and passes under one of the raised rails, while the body of the coupler rests on top of the rail.

Alternative couplers may be selected that have an appropriate vehicle interface 18 for clamping or otherwise connecting the coupler to an alternative vehicle feature, such as for example a fixed-point style of coupler suitable for connecting to a base portion fixed to a vehicle rooftop, a naked-roof style of coupler suitable for connecting the coupler to a gutter or other slot running along a side of the vehicle rooftop, or a two-clip flush rail type of coupler suitable for connecting the coupler to a flush rail feature of a vehicle, among others.

Examples, Components, and Alternatives

The following sections describe selected aspects of exemplary couplers, crossbar clamp actuators, crossbar clamps, and related systems and/or methods. The examples in these sections are intended for illustration and should not be interpreted as limiting the entire scope of the present disclosure. Each section may include one or more distinct inventions, and/or contextual or related information, function, and/or structure.

Illustrative Strap-Type Crossbar-To-Vehicle Coupler

As shown in FIG. 3, this section describes an illustrative strap-type coupler 68 having a crossbar clamp actuator 69 and a selectively tensionable resilient strap 70 used to secure coupler 68 to a raised roof rail of a vehicle. Coupler 68 is an example of couplers 16 described above. Accordingly, similar components may be labeled with similar reference numbers.

FIG. 3 is an oblique view of coupler 68 showing the interface provided by the coupler and clamp actuator. A bar clamp 71 is shown schematically, including a bar connector 72 and a bar seat 73, to illustrate that various such clamp components may be interchangeably utilized with clamp actuator 69. In similar fashion, clamp actuator 69 may be incorporated into various couplers. Accordingly, in some examples, this type of clamp actuator may be referred to as a universal connector, or the like.

As described above, coupler 68 includes a vehicle interface portion 74, a body 75, and a crossbar interface portion 76. Coupler 68 includes an outer case or housing 77, which in this example includes a locking feature 78 configured to prevent unwanted access to internal components. One or more portions of outer housing 77 may be selectively removable by a user.

As indicated schematically in FIG. 3, crossbar clamp 71 is configured to be attachable to a threaded member 79 of clamp actuator 69. Any suitable clamp may be used. In the examples described here and below, a two-piece clamp is utilized, comprising bar seat 73 and bar connector 72. In these examples, bar seat 73 includes any suitable structure configured to support the crossbar and function as an anvil against which the bar is secured (i.e., clamped). In some examples, bar seat 73 includes a crossbar-facing seating surface that conforms to an expected shape of the crossbar. In some examples, bar seat 73 is configured to nest on, mount to, or mate with a supporting surface 80 of coupler 68. One or more retaining features 81 of coupler 68 may be utilized (temporarily or otherwise) to hold bar seat 73 in place.

Crossbar connector 72 may include any suitable structure configured to be securely attachable to coupler 68 (e.g., at threaded member 79) and to capture, grab, connect with, encompass, slot into, engage, mate with, latch onto, or otherwise hold a portion of a crossbar. In some examples, different crossbar connectors may be provided corresponding to respective different types of crossbars.

Clamp actuator 69 includes any suitable structure and/or mechanism manually or automatically operable to urge bar connector 72 into a clamping position relative to bar seat 73, such that the connector and the bar seat secure the crossbar when clamped. For example, a portion of the crossbar may be clamped between the connector and the bar seat. In some examples, the actuator may pull the bar connector downward such that the crossbar is pulled with the connector and secured onto the crossbar seat. In some examples, actuator 69 may cause a pinching action between the bar connector and the bar seat, securing a portion of the crossbar. Actuator 69 may be reversibly operable, such that the same actuator may be used to disengage the clamp from the crossbar. In some examples, actuator 69 may be used to actively or affirmatively urge connector 72 away from crossbar seat 73. In some examples, actuator 69 may be used to release a securing force or pressure, such that the connector and seat can be manually separated.

In addition to securing clamp 71 to coupler 68, threaded member 79 may form a part of actuator 69. For example, rotation of threaded member 79 may, alone or in combination with other features, result in a clamping action. However, clamp operation via manipulation of threaded member 79 alone may require continued access to threaded member 79, which may not be desirable and/or practical in all operational situations or configurations. Accordingly, in some examples, clamp 71 is attached to the coupler and/or actuator by member 79, and actuator 70 includes a separate and/or related actuation mechanism.

In order to prevent undesired or unauthorized tampering with the actuator 69, which might otherwise permit the removal of the coupled crossbar and any load secured thereto, it may be desirable to prevent access to the actuation mechanism of actuator 69. For example, the actuation mechanism may be retained within body 75, and shielded by one or more portions of case or housing 77. Access to the actuation mechanism within body 75 may be secured by the locking feature 78.

Similarly, the vehicle interface portion 74 of the illustrative strap-type coupler 68 may include a securing assembly 83 configured to secure body 75 to raised roof rail 50, 52, as shown in FIG. 2. The securing assembly 83 may include an additional actuator 84 that may be made accessible by removing one or more portions of case or housing 77. As shown in FIG. 3, an outboard-facing portion of case 77 has been removed, permitting access to actuator 84 of the securing assembly 83. Even with the outboard-facing portion of case 77 removed, access to the actuation mechanism of actuator 69 is still prevented by locking mechanism 78.

Upon removal of locking mechanism 78, the actuator 85 for clamp actuator 69 may become accessible. Actuator 84 for securing assembly 83 and actuator 85 for clamp actuator 69 may be disposed on the same side of body 75. In particular, and as shown in FIG. 5, actuator 84 for the securing assembly 83 and actuator 85 for clamp actuator 69 may be disposed on the outboard-facing side of body 75, for the convenience of the user. Actuator 84 and actuator 85 may be disposed adjacent to one another, and may be vertically aligned so that the axis of rotation of actuator 84 and the axis of rotation of actuator 85 align within a vertical plane. Additionally, the axes of rotation of actuators 84 and 85 may align in a vertical plane that is parallel to the lateral axis 58, as shown in FIG. 2, which is itself parallel to the orientation of the crossbars 50 and 52 across the width of the vehicle roof. In one aspect of the disclosed coupler, the axes of rotation of actuators 84 and 85 lie in the same vertical plane as the longitudinal axis of the crossbar coupled to the vehicle via coupler 68.

The clamp actuator 69 and the securing assembly 83 may be independently adjustable. That is, actuator 84 and actuator 85 may be independently manipulated. Moreover, actuator 84 and actuator 85 may be configured to be operable using the same tool. For example, and as shown in FIG. 5, actuator 84 and actuator 85 are threaded bolts configured to be rotated using a single wrench or driver. For example, actuator 84 and actuator 85 may include allen bolts that may be configured to be rotated using the same size allen wrench.

Securing assembly 83 is shown in greater detail in FIGS. 6 and 7. As shown, securing assembly 83 includes resilient strap 70, and the securing assembly is configured such that a first end 86 of the resilient strap 70 is attached to body 75, and the second end 87 is selectively attachable to body 75, while the intervening portion of resilient strap 70 may be passed beneath the raised roof rail. Securing assembly 83 additionally includes a strap tightening mechanism 88 that is configured to reversibly shorten the effective length of the retention strap 70 in order to secure body 75 to the raised roof rail.

Resilient strap 70 may include any sufficiently flexible and durable material to secure coupler 68 to the selected roof rail. Strap 70 may include a high-density plastic, which is optionally reinforced by an insert to make the strap more resistant to cutting. For example, strap 70 may include a plastic strap with a metal strip either adhering to an inner surface of the strap, or completely incorporated within the plastic strap.

As shown in FIGS. 6 and 7, the first 86 and second 87 ends of strap 70 each include a loop structure 89, 90 that is disposed around and secured by a dowel portion 91 and 92, respectively. Dowel 91 of first end 86 of strap 70 is secured by a threaded bolt 93 that may be rotated via actuator 84. Strap 70 then passes over a pulley 94 disposed near the inboard side of the body 75, and then extends in the outboard direction so that second end 87 of strap 70 may be selectively secured to body 75 by retention structure 95.

Retention structure 95 may include two projecting ears 96 configured such that dowel 92 can rest upon ears 96. Rotation of actuator 84 in a clockwise direction results in dowel 91 being urged in the outboard direction, thereby tightening strap 70. As strap 70 comes under tension, the downward force on dowel 92 securely retains the second end 87 of strap 70 against ears 96 of retention structure 95. Rotation of actuator 84 in an anti-clockwise direction urges dowel 91 in the opposite, i.e. inboard, direction, increasing the effective length of strap 70, and permitting the second end 87 of strap 70 to be pulled upward and over the retention structure 95. The manipulation of the second end of strap 70, both to lift the second end up and rest dowel 92 upon retention structure 95, and to lift and remove the dowel 92 from the retention structure 95, may be facilitated by incorporating a handle in or on the second end of the strap, such as for example a loop handle.

FIG. 8 depicts the relationship between the clamp actuator 69 and the securing assembly 83 by removing selected portions of coupler 68. In particular, the close spatial relationship between actuator 84 and actuator 85 is clear, as is the orientation of both actuators on the outboard side of coupler 68. It should be further clear that clamp actuator 69 and securing assembly 83 are completely independent, permitting strap 70 or the selected crossbar clamp to be adjusted separately.

Illustrative Crossbar Clamp Actuator

As shown in FIG. 9, the presently disclosed strap-type coupler may be combined with a variety of different crossbars, crossbar clamps, and coupler styles. The clamp actuator described in this section is a schematic example of crossbar clamp actuator 28, described above.

A clamp actuator 310 is shown schematically in FIG. 9, and represents any example of clamp actuator 28 according to the present teachings (e.g., clamp actuator 202). In this type of clamp actuator, the substantially horizontal repositioning of a traveling wedge block causes its ramped slide surface to urge a wedge follower downward, thereby actuating (e.g., closing) the clamp.

As explained above, clamp actuator 310 is versatile in a first respect, in that various different clamps can be attached to the actuator. Generally speaking, a clamp that has a vertically repositionable jaw or other element may be connected to the attachment bolt of the clamp actuator. For example, a crossbar connector (e.g., connector 106, 136, or 176) may be connected to the attachment bolt, which protrudes in a generally vertical direction from an accessible upper support surface of the coupler. This is shown graphically in FIG. 9, where crossbar clamps 100′, 130′, and 170′ are depicted as optionally attachable to actuator 310. Crossbars 102′, 132′, and 172′ are shown with their corresponding clamps. A number of illustrative crossbar clamps will be discussed below.

When clamp actuator 310 is included in a coupler, the attachment bolt protrudes generally vertically from an upper surface of the coupler, and the tightening screw protrudes in an outboard direction from the coupler. Coupler 312 includes a crossbar interface 20 comprising a selected crossbar clamp and actuator described above, as well as a vehicle interface 18 for clamping or otherwise connecting the coupler to a vehicle feature. Specifically, coupler 312 is a strap-type coupler suitable for connecting the coupler to a raised rail feature of a vehicle. Raised rails generally include a pair of rails or bars each running parallel to the direction of vehicle travel and spaced above a respective lateral side of the rooftop. As discussed above for coupler 68, a strap 320 extends from a body 322 of this coupler, and is configured to pass under one of the raised rails while body 322 rests on top of the rail.

Illustrative Crossbar Clamps

This section describes three illustrative examples of crossbar clamps, as shown in FIGS. 10-13. These crossbar clamps are each an example of crossbar clamps 24 and 71, described above. As such, corresponding components may be labeled and/or associated with the same or similar reference numbers.

FIG. 10 depicts an illustrative clamp 100 suitable for use with a substantially round crossbar 102. Clamp 100 includes a crossbar seat 104 and a crossbar connector 106. Crossbar seat 104 may include any suitable structure configured to cradle crossbar 102 on a seating surface 108 that generally conforms to an outer surface 110 of the crossbar. Crossbar seat 104 may be described as an anvil or a fixed jaw. In some examples, seating surface 108 may include a resilient, compressible, and/or compliant layer, such as a rubber coating, to reduce damage to crossbar 102.

Crossbar connector 106 may include any suitable structure configured to capture (e.g., grasp or grip) crossbar 102, and to be movable relative to crossbar seat 104, such that the captured crossbar can be urged or forced against seating surface 108. Crossbar connector 106 may be interchangeably referred to as a crossbar capturing member or crossbar capturing portion of clamp 100.

In this example, crossbar connector 106 includes a sleeve portion 112 and a stem portion 114. Sleeve portion 112 is a substantially cylindrical tube or collar generally conforming to but slightly larger than an outer diameter of the round crossbar. Sleeve portion 112 may freely slide on crossbar 102. Stem portion 114 extends or protrudes radially from an outer surface of sleeve portion 112. Stem portion 114 may include a fastening mechanism, such as a threaded hole, for attaching connector 106 to a clamp actuator.

Crossbar seat 104 includes a block having an aperture 116 running vertically through the block, and through which crossbar connector 106 can at least partially extend. For example, stem portion 114 may extend through aperture 116. In some examples, stem portion 114 may be connectible to an actuator, such that the actuator can pull crossbar connector 106 downward through aperture 116. As can be seen in FIG. 4, this action causes crossbar 102 to be pulled down onto crossbar seat 104, thereby arresting the downward motion of the crossbar connector and clamping the crossbar in place. As depicted in FIG. 4, a lower inner surface 118 of sleeve portion 112 may be pulled below seating surface 108. This may be facilitated by the larger diameter of sleeve portion 112 and/or an elastic deformation of sleeve portion 112 as a downward force is applied by the actuator. In some examples, crossbar 102 may be a steel crossbar and sleeve portion 112 may comprise aluminum.

Crossbar seat 104 also includes a retention ridge 120. A respective instance of ridge 120 may be present on one or more surfaces of seat 104, and may be configured to interface with a corresponding retaining feature, e.g., retaining feature 81 described above with respect to FIG. 3. For example, seat 104 may click into place with retaining feature 81 grabbing onto ridge 120 to hold the crossbar seat block in place on the coupler. Holding the crossbar seat in place may be temporary, as the crossbar seat is secured in place by subsequent clamping of the crossbar.

Crossbar seat 104 is supported on the coupler. Accordingly, a lower mating surface 122 may be shaped to engage or otherwise fit onto a corresponding support surface of the coupler (e.g., support surface 80 described above with respect to FIG. 3). As described below regarding similar crossbar seats, lower mating surface 122 may include one or more additional features, such as discrete positioning teeth, a selected curvature, etc.

FIGS. 11 and 12 depict another illustrative clamp 130 suitable for use with a slotted crossbar 132. FIG. 11 is an exploded isometric view of clamp 130, and FIG. 12 is an end view of clamp 130 assembled and inserted into a longitudinal bottom slot of crossbar 132, which is shown in section view.

Clamp 130 includes a crossbar seat 134 and a crossbar connector 136. Similar to crossbar seat 104, crossbar seat 134 may include any suitable structure configured to cradle crossbar 132 on a seating surface 138 that generally conforms to an outer surface 140 of the crossbar. Crossbar seat 134 may be described as an anvil or a fixed jaw. In some examples, seating surface 138 may include a resilient, compressible, and/or compliant layer, such as a rubber coating, to reduce damage to crossbar 132.

Crossbar connector 136 may include any suitable structure configured to capture (e.g., grasp or grip) crossbar 132, and to be movable relative to crossbar seat 134, such that the captured crossbar can be urged against seating surface 138. Crossbar connector 136 may be interchangeably referred to as a crossbar capturing member or crossbar capturing portion of clamp 130. In this example, crossbar connector 136 may be referred to as a tee or a mushroom.

Crossbar connector 136 includes a flange portion 142, also referred to as a cap or tee portion, and a stem portion 144. Flange portion 142 is a substantially planar plate or flange sized to slide into a tee slot 146 (also referred to as a T-slot) of slotted crossbar 132. Tee slot 146 runs longitudinally along a length of crossbar 132, and comprises a pair of spaced apart lips 148 and 150 defining a gap (i.e., slot 146) therebetween. Flange portion 142 has a width that spans slot 146, such that bottom surfaces of the flange portion may abut upper surfaces of lips 148 and 150 of the tee slot. Stem portion 144 extends or protrudes orthogonally from flange portion 142. Stem portion 144 may be sized such that stem portion 144 can extend through slot 146 when flange portion 142 is inserted in the slot, as shown in FIG. 11. Accordingly, crossbar connector 136 may freely slide in a longitudinal direction along slot 146 of crossbar 132 when clamp 130 is unclamped.

Stem portion 144 may include a fastening mechanism, such as a threaded hole, for attaching connector 136 to a clamp actuator. Similar to the way sliding sleeve portion 112 onto crossbar 102 captured that crossbar, inserting crossbar connector 136 into tee slot 146 effectively captures crossbar 132.

Crossbar seat 134 includes a block having an aperture 152 running vertically through the block, and through which crossbar connector 136 can at least partially extend. For example, stem portion 144 may extend through aperture 152, as shown in FIG. 12. In some examples, stem portion 144 may be connectible to an actuator, such that the actuator can pull crossbar connector 136 downward through aperture 152. As can be seen in FIG. 12, this action will cause flange 142 to exert force on lips 148 and 150, pulling crossbar 132 down onto crossbar seat 134, thereby arresting the downward motion of the crossbar connector and clamping the crossbar in place. (See FIGS. 13-14).

Crossbar seat 134 may include a pair of guide flanges 154 and 156 protruding from seating surface 138 on opposing sides of aperture 152. Guide flanges 154 and 156 may include any suitable structures axially aligned with each other and configured to mate in sliding engagement with crossbar slot 146. As with flange portion 142 of crossbar connector 136, guide flanges 154 and 156 may be passed into slot 146 through an end of the crossbar, in an axial direction with respect to the long axis of the crossbar. Guide flanges 154 and 156 are positioned on either end of flange portion 142 of the bar connector when assembled. Guide flanges 154 and 156 may be unitary with crossbar seat 134.

The guide flanges may function to maintain an orientation of the crossbar seat with respect to the crossbar slot and/or to keep seat 134 adjacent to the crossbar, e.g., during assembly and adjustment. Guide flanges 154 and 156 may not be load bearing structures. For example, clamping force may be applied to crossbar 132 by drawing bar connector 136 down onto crossbar seat 134. Flanges 154 and 156 are fixed relative to crossbar seat 134. Consequently, the guide flanges may not exert any substantive vertical force on the crossbar during a clamping operation.

Crossbar seat 134 also includes a retention ridge 158, substantially similar to ridge 120 described above. As with crossbar seat 104, a lower mating surface 160 may be shaped to engage or otherwise fit onto a corresponding support surface of the coupler (e.g., support surface 80 described above with respect to FIG. 3). Lower mating surface 160 may include one or more additional features, such as discrete positioning teeth 162 configured to mate with corresponding teeth or features on the support surface of the coupler.

FIG. 13 depicts another illustrative clamp 170 suitable for use with an aerodynamic (also referred to as “aero”) or teardrop shaped crossbar 172. Aero crossbar 172 may or may not include a lower T-slot, similar to crossbar 132. However, crossbars having lower T-slots frequently also have such slots on upper surfaces, and clamp 170 may interfere with these upper slots. Accordingly, it may be desirable to use clamp 130 rather than clamp 170 in some examples, and vice versa.

Clamp 170 includes a crossbar seat 174 and a crossbar connector 176, both of which are similar to their corresponding components in clamp 100. Crossbar seat 174 may include any suitable structure configured to cradle crossbar 172 on a seating surface 178 that generally conforms to an outer surface 180 of the crossbar. Crossbar seat 174 may be described as an anvil or a fixed jaw. In some examples, seating surface 178 may include a resilient, compressible, and/or compliant layer, such as a rubber coating, to reduce damage to crossbar 172.

Crossbar connector 176 may include any suitable structure configured to capture (e.g., grasp or grip) crossbar 172, and to be movable relative to crossbar seat 174, such that the captured crossbar can be urged against seating surface 178. Crossbar connector 176 may be interchangeably referred to as a crossbar capturing member or crossbar capturing portion of clamp 170.

In this example, crossbar connector 176 includes a sleeve portion 182 and a stem portion 184. Sleeve portion 182 is a substantially teardrop-shaped or airfoil-shaped tube or collar generally conforming to but slightly larger than an outer shape of the aero crossbar. Sleeve portion 182 may freely slide on crossbar 172. Stem portion 184 extends or protrudes outward from an outer surface of sleeve portion 182. Stem portion 184 may include a fastening mechanism, such as a threaded hole, for attaching connector 176 to a clamp actuator.

Seating surface 178 of crossbar seat 174 may include two raised wall portions 186, 188 defining a central channel 190, and may have an aperture 192 passing vertically through the crossbar seat. Crossbar connector 176 can at least partially extend through aperture 192, and sleeve 182 may be nestable in channel 190, as shown in FIG. 13. Stem portion 184 may extend through aperture 192 when clamp 170 is assembled.

In some examples, stem portion 184 may be connectible to an actuator, such that the actuator can pull crossbar connector 176 downward through aperture 192. As can be seen in FIG. 13, this action will cause crossbar 172 to be pulled down onto crossbar seat 174, thereby arresting the downward motion of the crossbar connector and clamping the crossbar in place. As depicted in FIG. 13, a lower inner surface 194 of sleeve portion 182 may be pulled below seating surface 178. This may be facilitated by the larger diameter of sleeve portion 182 and/or an elastic deformation of sleeve portion 182 as a downward force is applied by the actuator. In some examples, crossbar 172 may be a steel crossbar and sleeve portion 182 may comprise aluminum.

Crossbar seat 174 also includes a retention ridge 196. A respective instance of ridge 196 may be present on one or more surfaces of seat 174, and may be configured to interface with a corresponding retaining feature, e.g., retaining feature 81 described above with respect to FIG. 3. For example, as with other crossbar seats, seat 174 may click into place with retaining feature 94 grabbing onto ridge 196 to hold the crossbar seat block in place on the coupler. Holding the crossbar seat in place may be temporary, as the crossbar seat is secured in place by subsequent clamping of the crossbar.

Crossbar seat 174 is supported on the coupler. Accordingly, a lower mating surface 198 may be shaped to engage or otherwise fit onto a corresponding support surface of the coupler (e.g., support surface 80 described above with respect to FIG. 3). As described above, lower mating surface 198 may include one or more additional features, such as discrete positioning teeth, a selected curvature, etc.

Illustrative Crossbar Clamp Actuator

As shown in FIGS. 14-20, this section describes an illustrative clamp actuator (also referred to as an actuator mechanism or actuator assembly) suitable for use in a coupler to tighten crossbar clamps similar to those described above. The clamp actuator described in this section is an example of crossbar clamp actuator 28, described above, and is similar to actuator 69 shown in FIG. 3. As such, corresponding components may be labeled and/or associated with the same or similar reference numbers.

As described above, actuation of crossbar clamps such as clamps 100, 130, and 170 includes repositioning of a portion of the clamp (e.g., a clamp jaw or crossbar connector) in a substantially downward direction, e.g., along a vertical path. For example, clamp 100 is actuated by applying a downward force to (e.g., pulling downward on) stem portion 114, thereby drawing bar connector 106 down with respect to bar seat 104. Because crossbar 102 is captured by the encircling bar connector 106, crossbar 102 is pinned against bar seat 104 as a result. Similarly, clamp 130 is actuated by applying a downward force to stem portion 144, thereby drawing bar connector 136 down with respect to bar seat 134. Because crossbar 132 is captured by bar connector 136 being inserted in slot 146, crossbar 132 is pinned against bar seat 134 as a result. This downward-force style of actuation may also be true for other types of clamps.

Accordingly, in these examples, a suitable actuator should provide a downward force to the crossbar connector portion of the crossbar clamps. Furthermore, it may be advantageous for a manual actuator to be accessible from an outboard side of the coupler, such that a user may operate the actuator easily when the coupler is mounted on a vehicle. Such a crossbar clamp actuator is described below, in which manipulation of a horizontal tightening member is mechanically translated into a downward clamping action.

In FIG. 14, a crossbar clamp 200 and a crossbar clamp actuator 202 are depicted in an exploded view. Any suitable crossbar clamp, such as the ones described above, may be used with actuator 202. In this example, crossbar clamp 200 is substantially identical to crossbar clamp 170, and includes a crossbar connector 204 and a crossbar seat 206. Crossbar connector 204 is a collar-type connector having a sleeve portion 208 and a stem portion 210. Crossbar seat 206 includes a pair of side walls 212 and 214 defining a seating surface 216 for an aero crossbar (not pictured), a central channel 218, and an aperture 220. A rounded lower surface of the crossbar seat includes positioning teeth 222 for positively locating the crossbar seat on the housing described below.

Stem portion 210 of the crossbar connector includes a threaded hole 224 passing vertically through the stem. Stem portions of other crossbar clamps may include similar threaded holes, which may or may not pass completely through the stem. These threaded holes may be used to fasten a selected clamp to the attachment bolt of the actuator (see below), which corresponds to threaded member 79 of FIG. 3. Stem portion 210 may have a shaped lower profile. In this example, the lower profile is stepped or keyed to provide a mating surface for the wedge follower described further below.

As shown in FIG. 14, actuator 202 (also called an actuator assembly) includes a housing 226, a traveling wedge block 228 (also called a slide wedge or wedge portion), a wedge follower 230 (also called a slide follower), an attachment bolt 232 (also called a second threaded member), a tightening screw 234 (also called a first threaded member) for positioning the traveling wedge block, and a security cover 236.

Housing 226 may include any suitable structure(s) configured to provide a support surface 238 for crossbar seat 206, to define a cavity 240 for housing wedge block 228 and wedge follower 230, and to provide a stationary fulcrum or brace against which the mover of the wedge block can apply force. In this example, the mover of the wedge block is tightening screw 234. Accordingly, a head 242 of the tightening screw abuts and turns against a substantially vertical plate 244 (i.e., a wall) of housing 226, which provides a stationary structural abutment. The tightening screw passes through an hole 246 in the plate. Hole 246 may be elongated and/or arcuate, facilitating side to side adjustment within the hole and/or minor rotation/tilting of traveling wedge block 228. A washer may be disposed between head 242 and plate 244. In other examples, the mover of the traveling wedge block may include a cam mechanism, a lever, and/or the like.

In this example, housing 226 is a unitary, box-like structure having an open bottom (e.g., a five-sided box). Housing 226 includes features for attaching the housing to other components or otherwise integrating the housing into a coupler, such as by riveting, bolting, screwing, adhering, and/or the like, or any combination of these. For example, housing 226 includes mounting structures 248, 250, and 252. In some examples, housing 226 comprises separate components, attached to each other and/or to other features of the host coupler. For example, rather than an integral portion of the housing, plate 244 may comprise a separate component bolted in position to the body of the coupler (e.g., see FIG. 3).

Support surface 238, which comprises an upper portion of housing 226, may have any suitable structures configured to mate with and/or support crossbar seat 206 thereon, for example in a selected orientation. In this example, support surface 238 includes features that conform to corresponding features of the crossbar seat. For example, raised edges 254 and 256 are configured to positively locate and cradle the general shape of seat 206, and teeth 258 and 260 are configured to mate with teeth 222 to hold the crossbar seat in position. Support surface 238 further includes an aperture 262. In this example, aperture 262 in the housing is generally rectangular and corresponds positionally to aperture 220 of the crossbar seat. This positional correspondence allows, e.g., stem 210 of the crossbar connector to pass through the two aligned apertures when the components are assembled.

As depicted in FIGS. 14 and 15, traveling wedge block 228 is a generally rectangular block having a threaded hole 264 in an outboard end. Threaded hole 264 is configured to accept tightening screw 234, such that rotation of the tightening screw causes wedge block 228 to move horizontally toward or away from plate 244 (i.e., in an outboard or inboard direction). Wedge block 228 includes one or more ramped, downward-facing slide surfaces, in this example the wedge block includes a pair of such surfaces 266 and 268. In this example, slide surfaces 266 and 268 are generally parallel to each other, and ramp downward toward the inboard end of the wedge block. In some examples, the one or more slide surfaces may instead ramp upward toward the inboard end.

Traveling wedge block 228 is open at the bottom, such that the ramped slide surfaces are exposed. An elongate aperture 270 exists between slide surfaces 266 and 268. Aperture 270 generally aligns with apertures 220 and 262. Maintenance of this alignment during operation is facilitated by the elongated shape of aperture 270 in the wedge block's direction of travel.

Side surfaces of traveling wedge block 228 may include hooks or protrusions 272, as shown in FIGS. 14 and 15. Hooks 272 facilitate attachment of security cover 236 to wedge block 228, such that the security cover moves with the wedge block when tightening screw 234 is rotated. Security cover 236 may be clipped or otherwise coupled to the wedge block, for example by mating holes 274 of the security cover with corresponding hooks 272.

With reference now to FIGS. 14 and 16-18, wedge follower 230 is a movable component having an upper interface 276 for mating with stem 210 of crossbar connector 204. Wedge follower 230 further includes a central aperture 278 passing vertically through the wedge follower (and through which attachment screw 232 may pass), and a pair of wedge-shaped side protrusions 280, 282.

Side protrusions 280 and 282 each have a ramped upper slide surface 284, 286 configured to make frictional, flat-to-flat contact with a respective one of slide surfaces 266 and 268 when the wedge follower is placed into the open bottom of the traveling wedge block. Upper slide surfaces 284 and 286 may be ramped planes, such that the upper slide surfaces mate with correspondingly angled and planar slide surfaces 266 and 268 of the sliding wedge block. As indicated in FIG. 16, the ramped surface of each side protrusion may define an angle A, which may be complementary to an angle B of the correspondingly-ramped planes of surfaces 266 and 268. This flat-to-flat contact facilitates a sliding motion and opposes twisting of the wedge block and wedge follower components relative to each other when in operation.

Accordingly, horizontal repositioning of wedge block 228, e.g., in an outboard or first direction, will cause slide surfaces 266 and 268 to reposition horizontally on side protrusions 280, 282 of the wedge follower. When assembled, wedge follower 230 is substantially blocked from moving in an outboard direction but free to move in a direction orthogonal to the outboard direction (e.g., vertical). Because slide surfaces 266 and 268 are ramped, horizontal repositioning of wedge block 228 will cause a wedging action, such that the side protrusions and wedge follower 230 are urged downward (i.e., orthogonal to the first direction of the wedge block). The downward motion of wedge follower 230 may appear vertical when viewed in a direction of vehicle travel, but may be slightly off-vertical when viewed along the long axis of the crossbar. This is because the traveling wedge block may be oriented in a rotated position with respect to its long axis. Accordingly, “vertical” travel of the wedge follower may actually be normal to the plane generally defined by the width of the wedge block.

To transfer this forced downward motion to crossbar connector 204, thereby causing a clamping action, attachment bolt 232 (also referred to as an attachment screw, a retention member, a threaded member, a second threaded member) passes vertically through aperture 278 of wedge follower 230 and fastens to crossbar connector 204 via threaded hole 224 in stem 210. In some examples, aperture 278 may be threaded. In some examples, aperture 278 may be an unthreaded through-hole. Attachment screw 232 may be held in position (when not attached to the crossbar connector) by a C-clip, E-clip, or snap ring installed at the upper exit of aperture 278 (see FIG. 3). Various crossbar connector styles may be interchangeably attached to the coupler and actuator assembly using the same attachment bolt.

When wedge follower 230 is coupled to crossbar connector 204 by attachment bolt 232, the shaped bottom of stem 210 nests in the correspondingly shaped upper interface 276 of wedge follower 230. For example, upper interface 276 may include castellations 288, such that crossbar connector 204 is prevented from twisting relative to wedge follower 230 by the castellated mating surfaces. Attachment of a crossbar connector to the wedge follower is complete when the stem is seated on the wedge follower and the attachment bolt is fully tightened. In this illustrative actuator system, attachment bolt 232 is only for securing crossbar connector 204 to the assembly, and bolt 232 is not used to directly actuate the clamp.

Security cover 236 may include any suitable structure configured to prevent access to attachment bolt 232. For example, as shown in FIG. 14, security cover 236 may include a sheet of metal or other tamper-resistant material that covers the head of bolt 232 to prevent unwanted tampering. In this example, the cover is removably attachable to traveling wedge block 228 and shaped such that repositioning of the wedge block in an outboard (i.e., clamp-tightening) direction causes the security cover to block access to the bolt. Conversely, the bolt head may be uncovered when the wedge block is repositioned in a clamp-loosening direction (i.e., inboard).

Illustrative Clamp Actuation

Turning now to FIGS. 19 and 20, actuator 202 is assembled, combined with clamp 130, and shown in a sectional side elevation view. Line 13-13 of FIG. 15 indicates generally where the cross section is taken with respect to traveling wedge block 228. FIG. 19 shows the actuator and clamp in a first, unclamped configuration, and FIG. 20 shows the same actuator and clamp in a second, clamped configuration.

As described above, actuator 202 may be combined with various crossbar clamps and corresponding crossbars. In this example, actuator 202 is combined with crossbar clamp 130 by bolting stem 144 of crossbar connector 136 to wedge follower 230 (using attachment bolt 232). Crossbar clamp 130 and actuator 202 are incorporated into an exemplary coupler 300, which is shown in engagement with T-slot crossbar 132.

In FIG. 19, crossbar 132 is seated on crossbar seat 134, with guide flanges 154 and 156 inserted into the crossbar slot. The crossbar is captured by flange 142 of crossbar connector 136, and stem 144 extends downward through the crossbar slot. However, flange 142 is in a raised position relative to lip 148 of the crossbar. In other words, clamp 130 is in an unclamped position, and flange 142 is not applying force to hold the crossbar against the crossbar seat.

With continuing reference to FIG. 19, stem 144 extends from flange 142 through the crossbar slot and through aperture 152 of crossbar seat 134 to mate with the castellated support surface of wedge follower 230. Wedge follower 230 is generally disposed within traveling wedge block 228, with the upper slide surfaces of the wedge follower's side protrusions in frictional contact with the slide surfaces of the traveling wedge block. For example, upper slide surface 284 is shown in contact with slide surface 266. It should be understood that upper slide surface 286 is similarly in contact with slide surface 268, but that this portion of the assembly is obscured in FIGS. 19 and 20. In the unclamped configuration shown in FIG. 19, traveling wedge block 228 is horizontally spaced from plate 244 of housing 226, and held in position by tightening screw 234.

Turning to FIG. 20, traveling wedge block 228 has been horizontally repositioned in an outboard direction (i.e., to the right in the drawing), by rotation of tightening screw 234, such that the traveling wedge block is now closer to plate 244. Rotation of screw 234 may be performed by any suitable method, such as using a driver or other tool configured to mate with screw head 242. This repositioning of wedge block 228 is generally indicated by an arrow 302.

As described above, wedge follower 230 is bolted to stem 144 of crossbar connector 136. Furthermore, the assembled wedge follower and crossbar connector are blocked from moving horizontally by the confines of the various apertures they pass through (e.g., apertures 152, 262, 270). However, the wedge follower/crossbar connector assembly does have some freedom to move up and down.

When wedge block 228 is repositioned as shown, ramped, downward-facing slide surfaces 266 and 268 are also moved in the outboard direction. This changes the effective vertical position of slide surfaces 266 and 268 at their point of interaction with the side protrusions, thereby applying a downward force on the side protrusions. Side protrusions 266 and 268 may have any suitable profile shape, and may comprise round pins or other shapes. In this example, side protrusions 266 and 268 have ramped planar surfaces that complement the ramped planar faces of surfaces 266 and 268. As described above, this feature helps to prevent twisting and other undesired moments. In some examples, this feature increases the frictional contact area between the wedge block and wedge follower, which may improve holding forces and prevent loosening of the overall mechanism.

Application of the downward force on side protrusions 266 causes wedge follower 230 and therefore the crossbar connector 136 to move along a downward path, as indicated by an arrow 304 in FIG. 20. This downward movement brings flange 142 down onto lips 148 and 150, and secures (i.e., clamps) crossbar 132 against crossbar seat 134. Accordingly, actuator 202 translates the repositioning of traveling wedge block 228 in a first direction (e.g., horizontal) into the repositioning of crossbar connector 136 in a second direction (e.g., substantially vertical), where the second direction is substantially orthogonal to the first direction. Said another way, actuator 202 translates rotational manipulation of a horizontal member (i.e., tightening screw 234) into substantially vertical tightening of a clamp portion (i.e., connector 136). It should be understood that the terms horizontal and vertical are used here in the context of the standard mounting position of the coupler. Other mutually orthogonal or otherwise transverse directions may be substituted without going beyond the scope of the present disclosure.

Selected Aspects and Examples

This section describes additional aspects and features of crossbar clamp actuators and related systems and methods, presented without limitation as a series of paragraphs, some or all of which may be alphanumerically designated for clarity and efficiency. Each of these paragraphs can be combined with one or more other paragraphs, and/or with disclosure from elsewhere in this application, including the materials incorporated by reference in the Cross-References, in any suitable manner. Some of the paragraphs below expressly refer to and further limit other paragraphs, providing without limitation examples of some of the suitable combinations.

Advantages, Features, Benefits

The different embodiments and examples of the strap-type vehicle-to-crossbar coupler and related systems and methods described herein provide several advantages over known solutions for mounting crossbars on vehicles. For example, illustrative embodiments and examples described herein facilitate the use of interchangeable crossbar clamps on the same strap-type coupler suitable for mounting on a vehicle having raised roof rails.

Additionally, and among other benefits, the illustrative embodiments and examples described herein permit the independent adjustment of the securing assembly and the crossbar clamp actuator, so that the connection between the coupler and a roof rail need not be compromised in order to change the type of crossbar and crossbar clamp attached to the coupler. In addition, a large variety of different crossbars and crossbar clamps may be used with the disclosed couplers, enhancing their versatility.

Additionally, and among other benefits, the actuator for the securing assembly and the actuator for the clamp actuator are disposed adjacent one another on an outboard side of the coupler, in close vertical alignment, and the two actuators may be adjusted using a single tool. In this way any desired adjustment by the user of the coupler, or of the rack system incorporating the coupler, is streamlined and simplified.

No other known system or device can perform all of these functions. However, not all embodiments and examples described herein provide the same advantages or the same degree of advantage.

CONCLUSION

The disclosure set forth above may encompass multiple distinct examples with independent utility. Although each of these has been disclosed in its preferred form(s), the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense, because numerous variations are possible. To the extent that section headings are used within this disclosure, such headings are for organizational purposes only. The subject matter of the invention(s) includes all novel and nonobvious combinations and subcombinations of the various elements, features, functions, and/or properties disclosed herein. The following claims particularly point out certain combinations and subcombinations regarded as novel and nonobvious. Other combinations and subcombinations of features, functions, elements, and/or properties may be claimed in applications claiming priority from this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure. 

What is claimed is:
 1. A rack for carrying cargo on top of a vehicle, the rack comprising: a crossbar for carrying cargo on top of a vehicle and a pair of coupler assemblies configured for connecting opposing end portions of the crossbar to raised rails on top of the vehicle; wherein each coupler assembly includes a body configured to rest upon an upper surface of the raised rail; a securing assembly configured to secure the body to the raised roof rail, the securing assembly including a resilient strap having a first end and a second end, the first end being attached to the body and the second end being selectively attachable to the body, such that an intervening portion of the resilient strap passes beneath the raised roof rail; and a strap tightening mechanism configured to reversibly shorten the effective length of the retention strap to secure the body to the raised roof rail; and a crossbar clamp, including a crossbar seat disposed on an upper surface of the body; a crossbar connector that is complementary to the crossbar and movable relative to the crossbar seat; and a crossbar clamp mechanism configured to urge the crossbar, via the crossbar connector, against the crossbar seat; wherein the securing assembly and the crossbar clamp are independently adjustable.
 2. The rack of claim 1, wherein a long axis of the crossbar is substantially horizontal and substantially perpendicular to a longitudinal axis of the vehicle.
 3. The rack of claim 1, wherein the crossbar connector includes a sleeve shaped to slide onto and generally conform to an outer shape of the crossbar.
 4. The rack of claim 1, wherein the crossbar connector includes a flange configured to slide into a slot of the crossbar, such that the flange spans a pair of opposing lips of the slot.
 5. The rack of claim 1, wherein the strap tightening mechanism includes a first actuator that is configured to reversibly shorten the effective length of the retention strap when rotated.
 6. The rack of claim 5, wherein the crossbar clamp mechanism includes a second actuator that is configured to urge the crossbar against the crossbar seat when rotated.
 7. The rack of claim 6, wherein the first actuator and the second actuator are disposed on a same side of the body.
 8. The rack of claim 6, wherein the first actuator and the second actuator are disposed on an outboard side of the body.
 9. The rack of claim 6, wherein the first actuator and the second actuator are configured to be rotated using a single tool.
 10. The rack of claim 1, wherein the crossbar clamp mechanism includes a traveling wedge block having a ramped first slide surface, and a movable wedge follower having a second slide surface in frictional contact with the first slide surface of the traveling wedge block; and the crossbar connector is movable with the wedge follower; so that repositioning the traveling wedge along a first path causes the ramped first slide surface to urge the wedge follower along a second path substantially orthogonal to the first path, such that the crossbar connector is urged closer to the crossbar seat, thereby clamping the crossbar against the crossbar seat.
 11. The rack of claim 10, wherein the crossbar clamp mechanism includes a second actuator that includes a threaded screw inserted into an end of the traveling wedge block, such that rotation of the threaded screw causes the horizontal repositioning of the traveling wedge block.
 12. A coupler assembly configured to connect an end portion of a crossbar to a raised rail on top of a vehicle; wherein each coupler assembly includes a body configured to rest upon an upper surface of the raised rail; a securing assembly configured to secure the housing to the raised roof rail, the securing assembly including a resilient strap having a first end and a second end, the first end being attached to the body and the second end being selectively attachable to the body, such that an intervening portion of the resilient strap passes beneath the raised roof rail; and a strap tightening mechanism configured to reversibly shorten the effective length of the retention strap when a first actuator is rotated and thereby secure the body to the raised roof rail; and a crossbar clamp, including a crossbar seat disposed on an upper surface of the housing; a crossbar connector that is complementary to the crossbar and movable relative to the crossbar seat; and a crossbar clamp mechanism configured to urge the crossbar, via the crossbar connector, against the crossbar seat when a second actuator is rotated; wherein the first actuator and the second actuator are independently adjustable.
 13. The coupler assembly of claim 12, wherein an axis of rotation of the first actuator and an axis of rotation of the second actuator are aligned in a vertical plane.
 14. The coupler assembly of claim 13, wherein the vertical plane is substantially parallel to a lateral axis of the crossbar.
 15. The coupler assembly of claim 12, wherein the first actuator and the second actuator are configured to be accessed at an outboard side of the body.
 16. The coupler assembly of claim 12, wherein the first actuator and the second actuator are threaded screws that are each configured to be rotatable with a single tool.
 17. The coupler assembly of claim 12, further comprising a locking feature configured to prevent unwanted access to at least one of the first and second actuator.
 18. The coupler assembly of claim 12, wherein the coupler assembly is configured so that the crossbar clamp mechanism can be loosened, and the crossbar connector can be replaced with a second crossbar connector that is complementary to a second crossbar without adjusting the securing assembly.
 19. The coupler assembly of claim 12, wherein the coupler assembly is configured so that the strap tightening mechanism can increase the effective length of the retention strap, and the second end of the resilient strap can be detached from the body, without adjusting the crossbar clamp or the crossbar connector.
 20. A rack for carrying cargo on top of a vehicle, the rack comprising: a crossbar for carrying cargo on top of a vehicle and a pair of coupler assemblies configured for connecting opposing end portions of the crossbar to raised rails on top of the vehicle; wherein each coupler assembly includes a body configured to rest upon an upper surface of the raised rail; a securing assembly configured to secure the body to the raised roof rail, the securing assembly including a resilient strap having a first end and a second end, the first end being attached to the body and the second end being selectively attachable to the body, such than an intervening portion of the resilient strap passes beneath the raised roof rail; and a strap tightening mechanism configured to reversibly shorten the effective length of the retention strap when a first actuator is rotated and thereby secure the body to the raised roof rail; and a crossbar clamp, including a crossbar seat disposed on an upper surface of the housing; a crossbar connector that is complementary to the crossbar and movable relative to the crossbar seat; and a crossbar clamp mechanism configured to urge the crossbar, via the crossbar connector, against the crossbar seat when a second actuator is rotated; wherein the first actuator and the second actuator are disposed in vertical alignment on an outboard side of the housing, and are configured to be independently adjusted using a single tool. 